Electronics-to-textile interconnection methodand system

ABSTRACT

An apparatus and method to reliably attach an electronic module to a textile. The overall mechanical assembly of the invention includes: (a) light pipe, (b) top enclosure, (b) magnet, (c) main electronics which contains (d) the main PCB, (e) battery and (f) other electronic components, (g) bottom enclosure, which holds (h) the connector PCB, (i) module dock, (j) top textile PCB which are located above the (j) textile band and under the (k) textile pocket and the (I) bottom textile PCB and (m) fabric and laminate padding, which are located below the textile band. The invention is physically embodied by an electronic module, comprising at least one printed circuit board (PCB), comprising at least one conductive circuit and at least one electronic component; a metallic rivet, grommet or eyelet to mechanically and electrically connect the; and a textile substrate with at least one electrically conductive circuit.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority from U.S. provisional patentapplication No. 62/614,380, filed on Jan. 6, 2018; the entire contentsof which are hereby incorporated by reference herein.

TECHNICAL FIELD

The present invention relates in general to smart textiles. Morespecifically, the present invention relates to a method and system ofconnecting electronic components to electrically conductive textiles.

BACKGROUND

Smart textiles are a fabric based system of materials and structuresthat sense and react to environmental conditions or stimuli, such asthose from mechanical, thermal, chemical, electrical, magnetic or othersources. Smart textiles can react or adapt to external stimuli orchanging environmental conditions. The stimuli can include changes intemperature, moisture, pH, chemical sources, electric or magneticfields, mechanical stress or strain.

Advanced smart textiles can have embedded computing, digital components,electronics, energy supply, and sensors. Basic components of smarttextiles include sensors, actuators, data transmission and electricalpower. When challenging functionality, size, cost, reliability, comfortand aesthetic/requirements are considered, there is an unmet need toseamlessly integrate electronic components into the manufacturing of thetextiles. Further, electrical connections between electricallyconductive circuits of the textiles (e.g. conductive fibres, wires, etc,of the textile substrate) with electronic components, such as powersources and computational components (e.g. processor, memory, etc.)require adaptable and/or reliable connection to the textiles.

Furthermore, textile manufacturing and electronics manufacturing usevastly different manufacturing infrastructures, utilizing highlydissimilar assembly equipment, materials and processes.

Hence, there is an urgent requirement for materials and manufacturingmethods which can easily integrate the interconnection of electronicsdevices or electronics modules into textile based substrates.

SUMMARY

Provides is a method and system for docking to obviate or mitigate atleast one of the above presented disadvantages.

A first aspect provided is a docking station assembly for providing areleasably secure connection between an electronic controller device andone or more conductive pathways of a textile substrate comprising: amodule dock station having a body fixedly connected to a substrateassembly mounted on the textile substrate, the body exposing anelectrical dock connector configured for mating with an electricalcontroller connector of the electronic controller device; the substrateassembly comprising: a first substrate positioned to one side of thetextile substrate, such that one or more first electrical connectionlocations of the first substrate are aligned with the one or moreconductive pathways, the first substrate having the electricalcontroller connector mounted thereon and electrically connected to theone or more first electrical connection locations by one or morerespective substrate conductive pathways; a second substrate positionedon the other side of the textile substrate opposite the one side, thesecond substrate having one or more second electrical connectionlocations aligned with the one or more first electrical connectionlocations; and one or more respective fasteners fastening the one ormore second electrical connection locations with the one or more firstelectrical connection locations, thus fixedly securing the textilesubstrate between the first substrate and the second substrate; whereinthe one or more first electrical connection locations are in electricalcontact with the adjacent one or more conductive pathways.

Provided is an apparatus and method to reliably attach an electronicmodule to a textile. The electronic module, comprises a printed circuitboard (PCB), comprising at least one conductive circuit and at least oneelectronic component; a mechanically and electrically connection to thetextile substrate; and the textile substrate with at least oneelectrically conductive circuit.

Optionally a rigid case to cover the PCB and electronic components onthe PCB, and, optionally, a pocket to hold the rigid case, preferablyknitted directly into the textile substrate. Finally, in a thirdoptional embodiment, a magnet system to inhibit the module from movingwithin the pocket.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated herein and form a partof the specification, illustrate the present invention and, togetherwith the description, further explain the principles of the inventionand to enable a person skilled in the pertinent art to make and use theinvention.

FIG. 1 illustrates an expanded (or exploded) view of the overallassembly;

FIG. 2 illustrates a perspective view of a substrate component of theoverall assembly of FIG. 1;

FIG. 3 illustrates a perspective view of a further substrate componentof the overall assembly of FIG. 1;

FIG. 4 illustrates a perspective view of the substrate component of FIG.2 in relation to the textile substrate of FIG. 1;

FIG. 5 illustrates a perspective view of a dock station body of FIG. 1in relation to the textile substrate of FIG. 1;

FIG. 6 provides an example of the electronic components of thecontroller device of FIG. 1;

FIGS. 7 and 8 provide views of the interior of the controller device ofFIG. 1;

FIG. 9, 10, 11 provide views of the substrate component of FIG. 3 inrelation to the textile substrate of FIG. 1;

FIG. 12, 13, 14 provide views of the controller device of FIG. 1 in bothassembled and unassembled;

FIG. 15 illustrates a cross-sectional view of the entire overallassembly of FIG. 1 after assembly;

FIG. 16 is an example view of the textile substrate of FIG. 1 includingconductive pathways; and

FIGS. 17-21 are example flowcharts of assembly methods for the overallassembly of FIG. 1.

DETAILED DESCRIPTION

In the following detailed description of the invention of exemplaryembodiments of the invention, reference is made to the accompanyingdrawings (where like numbers represent like elements), which form a parthereof, and in which is shown by way of illustration specific exemplaryembodiments in which the invention may be practiced. These embodimentsare described in sufficient detail to enable those skilled in the art topractice the invention, but other embodiments may be utilized andlogical, mechanical, electrical, and other changes may be made withoutdeparting from the scope of the present invention. The followingdetailed description is, therefore, not to be taken in a limiting sense,and the scope of the present invention is defined only by the appendedclaims.

In the following description, specific details are set forth to providea thorough understanding of the invention. However, it is understoodthat the invention may be practiced without these specific details. Inother instances, well-known structures and techniques known to one ofordinary skill in the art have not been shown in detail in order not toobscure the invention. Referring to the figures, it is possible to seethe various major elements constituting the apparatus of the presentinvention.

Referring to FIG. 1, shown is an expanded (or exploded) view of anoverall assembly 10 of a controller device 12 (e.g. electronic module)electrically connected to conductive pathways 80 (see FIG. 16) of atextile substrate 34 (e.g. in the form of a patch, band, shirt, pants,socks, undergarment, blanket, hat, glove, shoe, etc.) by way of a moduledock station 14. As such, the module dock station 14 (see FIG. 5) cancomprise a dock housing 50 having a body 14 a with an aperture 52 forproviding access between an electrical dock connector 54 (see FIG. 4)coupled to the conductive pathways 80 and an electrical controllerconnector 26 (see FIG. 1) that is connected to electronics 22 of thecontroller device 12, as further described below. The module dockstation 14 can also have one or more clips 55 (as an example of areleasably securable mechanism for mechanically coupling with thehousing 18,24 of the controller device 12). It is clear that the matingelectrical connection between the electrical dock connector 54 and theelectrical controller connector 26 is also releasably securable, thusfacilitating repeated installation and removal of the controller device12 with respect to the module dock station 14, both mechanically as wellas electrically.

Periodic removal of the controller device 12 could be advantageous forrecharging of a power source 70 (see FIG. 1) of the controller device12, replacement/substitution of the controller device 12 (including theelectronics 22), and/or temporary removal of the controller device 12for washing/cleaning purposes of the textile substrate 34 (e.g. whenwashing a garment which integrally incorporates the textile substrate 34as part of the overall garment construction).

Referring again to FIG. 1, the controller device 12 has a housing 18,24(e.g. a top enclosure and a bottom enclosure) providing a moistureresistant housing for the enclosed electronics 22. For example,referring to FIG. 6, the electronics 22 can include a power source 70(e.g. rechargeable battery) powering a memory 72 and a computerprocessor 74, such that the computer processor executes instructionsstore on the memory (e.g. ROM, RAM, etc.). The electrical connectionsbetween the electronics 22 can be by way of conductive pathways 76(shown in concept) on a printed circuit board (PCB) or other electronicssubstrate 78. The conductive pathways 76 can be electrically connectedto the electrical controller connector 26 (e.g. a socket connector—e.g.an 8 socket connector), such that the electrical controller connector 26can be considered as integral within the housing 18,24 (see FIG. 7). Assuch, the electrical controller connector 26 can be considered as partof the controller device 12.

The bottom enclosure 24 of the housing can include apertures 79 a forreceiving corresponding pins 79 b mounted on a body 54 a of theelectrical dock connector 54 (e.g. an 8 pin connector). It is alsoenvisioned that the electrical dock connector 54 can be a socketconnector and the electrical controller connector 26 can be a pinconnector 26 configured for mating with the socket connector 54. It isalso recognized that the electrical connectors 26,54 can have matingelectrical connections other than of the pin/socket type (e.g.magnetic), as desired, in so much that the electrical connectors 26,54are of the releasably securable type. As shown in FIG. 8, the electricalcontroller connector 26 can be sealed via a seal 82 (e.g. adhesive) withrespect to an interior surface 84 (of the housing 18,24 when assembled).The seal 82 can be used to inhibit moisture or other foreign matter fromentering into the interior 86 (see FIG. 7) via the apertures 79 a (seeFIG. 7).

Referring again to FIG. 1, the overall assembly 10 also includes a firstsubstrate 28 and a second substrate 30 for mounting on either side ofthe textile substrate 34. For example, the first substrate 28 can be aPCB. As shown in FIG. 2, the first substrate 28 has the electrical dockconnector 54 mounted thereon, with conductive pathways 43 connectingeach of the one or more electrical connectors 79 b (e.g. pins, sockets,etc.) of the electrical dock connector 54 with corresponding one or moreelectrical connection locations 42 mounted on the first substrate 28. Itis recognized that the one or more electrical connection locations 42can be distributed about a surface 28 a of the first substrate 28, suchthat each of the locations of the one or more electrical connectionlocations 42 correspond (e.g. in relative distance from one another)with the conductive pathways 80 (see FIG. 16) laid out on/in the textilesubstrate 34. The first substrate 28 can also have one or moreelectrical components 25 mounted thereon and thus electrically connectedto the electronics 22 via the mated connectors 26, 54 (pins/sockets) viacorresponding conductive pathway(s) 43. As shown, the first substrate 28can have a plurality of apertures 28 b corresponding in spatialdistribution with the spatial distribution of holes 34 b of the textilesubstrate 34 (see FIG. 4). The apertures 28 b are also matching inspatial distribution with a series of apertures 30 b of a surface 30 aof the second substrate 30 (e.g. a PCB). In assembly of the overallassembly 10, the first substrate 28 can be mounted on a correspondingsurface 34 a of the textile substrate 34 by an adhesive layer A. Inassembly of the overall assembly 10, the second substrate 30 can bemounted on a corresponding opposing surface 34 a of the textilesubstrate 34 by a similar adhesive layer A.

Referring to FIG. 3, the second substrate 30 is mounted on an oppositesurface 34 a of the textile substrate 34 to that used to mount the firstsubstrate 28, such that the textile substrate 34 is securely fastenedbetween the substrates 28, 30, as further described below. The secondsubstrate 30 also has connection locations 42 a corresponding to theelectrical connection locations 42, such that corresponding mechanicalfasteners 29 (e.g. rivets—see FIG. 2) can be used to mechanically fastenthe first substrate 28 to the second substrate 30, thus fixedlysandwiching/mounting the textile substrate 34 there-between).

Referring again to FIG. 4, an optional pocket 35 of the textilesubstrate 34 can be used to house the first substrate 28, as desired. Ascan be seen in FIG. 5, the optional pocket 35 can also be used to housethe module dock station 14, when fastened to the first substrate 28(further described below). Referring again to FIG. 1, the secondsubstrate 30 can be covered by an optional backing 32 (e.g. fabric,plastic, padding, laminate, etc.) material, so as to provide for comfortof the wearer of the textile substrate 34 (e.g. as incorporated into agarment), when the backing 32 material is in contact with a skin of thewearer. The overall assembly 10 can also include a light pipe 16 (forindicating functional status of the electronics 22 via one or morevisual indicators (e.g. LEDs) as well as a positioned magnet 20 in theinterior 86 of the housing 18, 24. In summary, the housing 18,24 of thecontroller device 12, once assembled, can be releasably secured, bothmechanically and electrically, with the module dock station 14. Themodule dock station 14 is fixedly attached to the first substrate 28,which is in term fixedly attached to the textile substrate 34 via themechanical (e.g. fasteners)/chemical (e.g. adhesive) connection betweenthe first substrate 28 and the second substrate 30 when positioned onopposed sides 34 a of the textile substrate 34.

Referring again to FIGS. 2, 3, 4, the apertures 28 b, 30 b and holes 34b can be used to fasten the module docking station 14 with thesubstrate(s) 28, 30 to one another, thus fixedly securing the moduledocking station 14 to the textile substrate 34. For example, onefastening method of the module docking station 14 with the substrate(s)28,30 can be using a staking method (see FIGS. 5, 9, 15), wherebystaking is the process of connecting the two components (the moduledocking station 14 with the substrate(s) 28,30) by creating aninterference fit of a fastener 90 between the two pieces (the moduledocking station 14 with the substrate(s) 28,30). One workpiece 28,30 hasa hole 28 b,30 b in it while the other (the module docking station 14)has a boss 90 that fits within the hole 28 b,30 b. It is recognized thatone of the workpieces 28, 30 can have the respective hole(s) 28 b, 30 bwhile the other of the pieces (the module docking station 14) can havethe fastener(s) 90 mounted on the corresponding surface 28 a,30 a. Thefastener 90 (e.g. boss) can be very slightly undersized so that it formsa slip fit with the hole 28 b,30 b. A staking punch can then used toexpand the boss 90 radially and to compress the boss 90 axially so as toform an interference fit between the workpieces (the module dockingstation 14 with the substrate(s) 28,30). This interference fit forms apermanent join(s)/connection(s) between the two pieces, such that theinterposed textile substrate 34 is fixedly secured between the twosubstrates 28,30 which in turn is fastened to the module docking station14 via the staking. The staking process can also be referred to asthermoplastic staking, also known as heat staking, which is the sameprocess except that it uses heat to deform the plastic boss 90, insteadof cold forming. A plastic stud 90 protruding from one component fitsinto a hole in the second component. The stud 90 is then deformedthrough the softening of the plastic to form a head which mechanicallylocks the two components (the module docking station 14 with thesubstrate(s) 28,30) together. Unlike welding techniques, staking has thecapacity to join plastics to other materials (e.g. metal, PCB's) inaddition to joining like or dissimilar plastics, and it has theadvantage over other mechanical joining methods in reducing the need forconsumables such as rivets and screws.

Referring to FIGS. 10 and 11, shown is an example backing 32 in order tocover the second substrate 30 after being fastened to the firstsubstrate 28. Referring to FIGS. 12, 13, 14, shown is the housing 18,24in an unassembled and assembled form, such that the interior 86 withmounted light pipe 16 and magnet 20 are shown by example. Referring toFIG. 16, shown is a cross sectional view of the overall assembly 10,including an optional piezo sensor mounted between the first substrate28 and the body 14 a of the module dock station 14.

Referring to FIG. 16, shown is an example textile substrate 34 with theconductive pathways 80, as an illustration only, with the locations ofthe electrical connector locations 42 (and/or fasteners 29) of FIG. 2 inghosted view. It is recognized that an electrical connection between theelectrical connector locations 42 and the conductive pathways 80 isfixed when the electrical connector locations 42 (of the first substrate28) come into contact with the conductive pathways 80, which ismaintained due to 1) the fixed connection (e.g. via fasteners 90)between the substrates 28, 30 thus sandwiching the textile substrate 34there between and biasing the electrical connectors locations 42 and theconductive pathways 80 into physical contact with one another; and/or 2)the connection via the fasteners 29 (e.g. conductive fasteners such asmetal rivets, pins, etc.) between the substrates 28,30 as the fasteners29 are in physical contact with the electrical pathways 80 as well asthe electrical connector locations 42. The substrates 28,30 can be madeof flexible or rigid material, as desired, so long as the materialretains the interconnection between the locations 42 by the fasteners29.

For example, electrical current to the electronics 22 follows theelectrically conductive path of: a) from the conductive pathways 76 tob) the electrical controller connector 26 to c) the electrical dockconnector 54 to d) the conductive pathways 43 connecting each of the oneor more electrical connectors 79 b (e.g. pins, sockets, etc.) of theelectrical dock connector 54 to e) corresponding one or more electricalconnection locations 42 to finally f) (e.g. via the fasteners 29)positioned adjacent to and electrically bonded to the conductivepathways 80 of the textile substrate 34. Similarly, electrical currentfrom the conductive pathways 80 of the textile substrate 34 follows theelectrically conductive path of: a) (e.g. via the fasteners 29)positioned adjacent to and electrically bonded to the conductivepathways 80 of the textile substrate 34 to b) corresponding one or moreelectrical connection locations 42 to c) the conductive pathways 43connecting each of the one or more electrical connectors 79 b (e.g.pins, sockets, etc.) of the electrical dock connector 54 to d) theelectrical dock connector 54 to e) the electrical controller connector26 to f) the conductive pathways 76 connected to the electronics 22.

In fabrication of the overall assembly 10, the following examplemanufacturing processes can be performed. FIG. 17 shows an exampleprocess 102 for manufacture of the textile substrate 34 including theconductive pathways 80 (e.g. circuits containing conductive wires/fibreswith attached sensors/actuators applied on or otherwise interlaced,knit/woven, with the fibres of the textile substrate 34). FIG. 18 showsan example method steps 104 to manufacture the sandwich of the twosubstrates 28, 30 with the textile substrate 34. Referring to FIG. 19,shown is a method 106 to fasten (e.g. mechanical) the module dockingstation 14 to the first substrate 28 underlying and adjacent to themodule docking station 14. Further, the backing 32 is fastened (e.g.adhesive) to the second substrate 30 underlying and adjacent to thebacking 32. FIG. 20 is an example manufacture 108 of the electricalcontroller connector 26 onto the housing 18,24 of the controller device12. FIG. 21 is a method of manufacture 110 for the main controllerdevice 12, including mounting of the components 16, 20, 22 within theinterior 86 of the housing 18,24 and sealing the housing 18,24.

As shown above by example, the overall assembly 10 included thecontroller device 12, the module dock station 14 fixedly connected tothe substrate(s) 28,30, and the substrates 28,30 fixedly connected tothe textile substrate 34 (having the plurality of conductive pathways80). As such, the controller device 12, once assembled, is bothmechanically and electrically releasably securable to the module dockstation 14, in order to effect electrical communication between theelectronics 22 of the controller device 12 and the conductive pathways80 of the textile substrate 34.

Accordingly, described by example only is: (a) light pipe 16, (b) topenclosure 18, (b) magnet 20, (c) main electronics 22 which can contain(d) the main PCB 28, (e) battery 70 and (f) other electronic components72,74,76, (g) bottom enclosure 24, which holds (h) the connector PCB 26,(i) module dock 14, (j) top textile PCB 28 which are located above the(j) textile band 34 and under the (k) textile pocket 35 and the (l)bottom textile PCB 30 and (m) fabric and laminate padding 32, which arelocated below the textile band 34.

Further, the embodiments comprise apparatus and methods to make areliable interconnection between electronic devices 12 and smarttextiles 34. The embodiments facilitate the electronic device 12 tomaintain a robust electrical connection to electrically conductivecircuits 80 on the smart textile 34 while also being securelymechanically fastened to the smart textile 34, thus acquiring theability to withstand mechanical shock, torsion, stretch and otherstresses to which the smart textile 34 or electronic devices 12 may besubject to.

In some embodiments the textile band 34 or textile substrate 34 maycontain no electrical or electronic components. In some embodiments, thetextile substrate 34 may contain only electrically conductive circuits80, such as electrically conductive yarn, fiber or printed electroniccircuits. In other embodiments, the textile substrate 34 may containfully functional and active electronic components, sensors, circuits andthe like.

For the purposes of a wearable smart textile 34 worn on the body, thedirection of below the textile band 34 would be interpreted as beingcloser to the body and above the textile band 34 would be farther awayfrom the body. The textile pocket 35 is preferably a structure which israised above the textile band 34 and fabricated by knitting into thetextile band 34 knit structure.

In some embodiments, the textile substrate 34 (also called the textileband 34) has successfully incorporated health monitoring sensors in theform of ECG sensor pads, respiratory monitoring sensors andbio-impedance monitoring sensors. These sensors are electricallyconnected to conductive circuits 80 within the textile band 34, whichare then connected using rivets 29, eyelet or grommets 42 leading to thehard electronics 22 (e.g. mounted on the PCB 78). In other embodiments,the main electronics PCB 78 has also successfully incorporated motionsensors and temperature sensors onto the module PCB 78, as part of theelectronics 22.

FIG. 17 illustrates embodiment comprising textile form factors to whichthe textile substrate 34 has been successfully applied, including:underwear, bra and shirts. It can be appreciated that the embodimentsare applicable to any form of textile substrate 34 or flexible substrate34 exhibiting similar properties to a textile or fabric.

FIG. 18 illustrates the steps relating to assembling the top textile PCB28 onto the textile band 34 with this embodiment comprising steps,including: (1) Placing an adhesive material A on the bottom side of thetop textile PCB 28, (2) Inserting the top textile PCB 28 inside thetextile pocket 35 by aligning the holes 42 on the top textile PCB 28 tothe matching pre-punched rivet holes 34 b onto the textile band 34, (3)Placing double-sided adhesive A on the bottom textile PCB 30 and placingit on the opposite side 34 a of the textile band 34 to the top textilePCB 28, also aligning to the pre-punched rivet holes 34 b in the textileband 34, and (4) Pressing the rivets 29 at the same time as applyingeven pressure to the PCBs 28,30.

Steps 1-4, above, create a robust and secure mechanical and electricalconnection between the top textile PCB 28, the bottom textile PCB 30 andthe textile band 34. In regions where an electrical connection isrequired, the pre-punched rivet holes 34 b in the textile band 34 can belocated such that an electrical conductive circuit 80 in the textileband 34 is physically in contact with the metal rivet 29 an/or theconductive locations 42 (e.g. part of the conductive pathways 43positioned on the underside of the first substrate 28 (and thus able tobe placed into direct contact with the surface 34 a of the textilesubstrate 34). It should be noted that rivet 29 can also mean eyelet,grommet or similar type of metal fastening method.

The textile band pocket 35, which is fabricated in such a manner as tobe raised above the surface 34 a of the textile band 34 facilitatingjust enough room for the module dock housing 50 to fit snugly within thepocket 35, while also facilitating it to be removed when necessary.

FIG. 19 illustrates the steps 106 relating to assembling the module dock14 and dock backing 32 into the textile band 34, with this embodimentcomprising steps, including: (1) Applying epoxy to the dock 14 andplacing it inside the pocket 35 by aligning the heat stacking poles 90to the holes 28 b, 30 b on the textile PCBs 28,30, (2) Heat staking thedock 14 onto the textile PCB 28,30,34 assembly, (3) Applying epoxy tothe dock backing 32 and placing it on the back of the bottom textile PCB30, and, (4) Covering the dock backing 32 with a fabric, preferablylaminated.

FIG. 20 illustrates the steps 108 relating to assembling the connectorPCB 26 into the bottom module enclosure 24 with this embodimentcomprising the steps of: (1) placing and press-fitting the connector PCBtarget discs 26 into the bottom module holes 79 a, (3) heat staking theconnector PCB 26 onto the dock body 14 a, (4) applying adhesive sealantaround the connector PCB 26 to prevent water ingression between the body14 a and the connector 26.

FIG. 21 illustrates the steps 110 relating to assembling the light pipe16 and magnet 20 and corresponding electronics 22 into the module topenclosure 18 and assembling the top 18 and bottom 24 module enclosurestogether with this embodiment comprising the steps of: (1) Press fittingand/or gluing the light pipe 16 into Module Top 18, (2) Press fittingand/or gluing the magnet 20 into Module Top 18 as well as connecting theelectronics 22 (e.g. via the PCB 78 together with the connector 26) inorder to electrically connect the conductive pathways 76 of theelectronics 22 with the connectors of the connector 26), (3) Assemblingthe Top 18 and Bottom 24 of the Module 12 together, and (4)Ultrasonically welding to seal the edges of the top 18 and bottom 24module.

Other options for manufacture can include generally processes such asbut not limited to:

1) the process of assembly comprises the steps of: assembling the toptextile PCB onto the textile band; placing an adhesive material on thebottom size of the top textile PCB; inserting the top textile PCB insidethe textile pocket by aligning the holes on the top textile PCB to thematching pre-punched rivet holes onto the textile band; placingdouble-sided adhesive on the bottom textile PCB and placing it on theopposite side of the textile band to the top textile PCB, also aligningto the pre-punched rivet holes in the textile band; and pressing therivets at the same time as applying even pressure to the PCBs;

2) in regions where an electrical connection is needed, the pre-punchedrivet holes in the textile band can be located such that an electricalconductive circuit in the textile band is physically in contact with themetal rivet;

3) the textile band pocket can be fabricated in such a manner as to beraised above the surface of the textile band providing just enough roomfor the module dock housing to fit snugly within the pocket, while alsoallowing it to be removed when used;

4) assembling the module dock and dock backing into the textile band;applying epoxy to the dock and placing it inside the pocket by aligningthe heat stacking poles to the holes on the textile PCBs; heat stakingthe dock onto the textile PCB assembly; applying epoxy to the dockbacking and placing it on the back of the bottom textile PCB; andcovering the dock backing with a fabric, preferably laminated;

5) assembling the connector PCB into the bottom module enclosure;placing and press-fitting the connector PCB target discs into the bottommodule holes; heat staking the connector PCB onto the dock; and applyingadhesive sealant around the connector PCB to prevent water ingression;and/or

6) assembling the light pipe and magnet into the module top enclosureand assembling the top and bottom module enclosures together; pressfitting and/or gluing the light pipe into Module Top; press fittingand/or gluing the magnet into Module Top; assembling the Top and Bottomof the Module together; and ultrasonically welding to seal the edges ofthe top and bottom module.

Thus, it is appreciated that the optimum dimensional relationships forthe parts of the invention, to include variation in size, materials,shape, form, function, and manner of operation, assembly and use, aredeemed readily apparent and obvious to one of ordinary skill in the art,and all equivalent relationships to those illustrated in the drawingsand described in the above description are intended to be encompassed bythe present invention.

Furthermore, other areas of art may benefit from this method andadjustments to the design are anticipated. Thus, the scope of theinvention should be determined by the appended claims and their legalequivalents, rather than by the examples given.

The embodiments of the invention in which an exclusive property orprivilege is claimed are defined as follows:
 1. A docking stationassembly for providing a releasably secure connection between anelectronic controller device and one or more conductive pathways of atextile substrate comprising: a module dock station having a bodyfixedly connected to a substrate assembly mounted on the textilesubstrate, the body exposing an electrical dock connector configured formating with an electrical controller connector of the electroniccontroller device; the substrate assembly comprising: a first substratepositioned to one side of the textile substrate, such that one or morefirst electrical connection locations of the first substrate are alignedwith the one or more conductive pathways, the first substrate having theelectrical controller connector mounted thereon and electricallyconnected to the one or more first electrical connection locations byone or more respective substrate conductive pathways; a second substratepositioned on the other side of the textile substrate opposite the oneside, the second substrate having one or more second electricalconnection locations aligned with the one or more first electricalconnection locations; and one or more respective fasteners fastening theone or more second electrical connection locations with the one or morefirst electrical connection locations, thus fixedly securing the textilesubstrate between the first substrate and the second substrate; whereinthe one or more first electrical connection locations are in electricalcontact with the adjacent one or more conductive pathways.
 2. Thedocking station assembly of claim 1, wherein the one or more respectivefasteners are electrically conductive and in physical contact with theone or more conductive pathways, thus contributing to said electricalcontact.
 3. The docking station assembly of claim 1 further comprising atextile pocket of the textile substrate for receiving the body.
 4. Thedocking station assembly of claim 3, wherein the textile pocket ispreferably a structure which is raised above an adjacent surface of thetextile substrate and fabricated by knitting into a knit structure ofthe textile substrate.
 5. The docking station assembly of claim 2,wherein the one or more respective fasteners are rivets.
 6. The dockingstation assembly of claim 1, wherein the one or more first electricalconnection locations are eyelets or grommets leading to the electricalcontroller connector via the one or more respective substrate conductivepathways
 7. The docking station assembly of claim 6, wherein the one ormore respective substrate conductive pathways are traces of PCBcircuitry, such that the first substrate is a PCB.
 8. The dockingstation assembly of claim 1, wherein the textile substrate isincorporated into a garment selected from the group consisting of: aband; underwear; a bra; and a shirt.
 9. The docking station assembly ofclaim 1 further comprising a releasable mechanical connector located onthe body, the releasable mechanical connector facilitating a releasablysecure mechanical connection between the controller device and the body.10. The device of claim 1, wherein the electrical dock connector mateswith the electrical controller connector via a pin and socketconfiguration.